Ransburg A11789 User Manual
Ransburg
MICROPAK
TM
CONTROLLER
SERVICE MANUAL
CP-06-01.1
(Replaces CP-06-01)
MARCH - 2013
MODEL: A11789
IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS, starting on
page 1, and all instructions in this manual. Keep
this Service Manual for future reference.
Service Manual Price: €25.00 (Euro)
$30.00 (U.S.)
CONTENTS
SAFETY:
MicroPak Controller - Contents
PAGE
1-5
SAFETY PRECAUTIONS............................................................................................................
HAZARDS / SAFEGUARDS........................................................................................................
INTRODUCTION:
GENERAL DESCRIPTION..........................................................................................................
SAFETY FEATURES...................................................................................................................
DISPLAYS....................................................................................................................................
CURRENT CONTROL................................................................................................................
SPECIFICATIONS.......................................................................................................................
INSTALLATION:
MICROPAK INPUT POWER.......................................................................................................
SAFETY GROUND......................................................................................................................
LOW VOLTAGE CABLE..............................................................................................................
INTERLOCKS AND I/O...............................................................................................................
DESCRIPTION OF TABLE 1 INTERLOCK &
I/O TERMINALS.........................................................................................................................
CURRENT CONTROL................................................................................................................
DIP SWITCH SUMMARY............................................................................................................
MICROPAK GROUND THEORY................................................................................................
OPERATION:
1
2-5
6-7
6
6
6
6
7
8-16
8
9
9
10-11
12
12-14
14-15
16
17-19
OPERATING CONTROLS..........................................................................................................
GENERAL OPERATING PROCEDURE....................................................................................
MAINTENANCE:
TROUBLESHOOTING................................................................................................................
CABLE CONTINUITY TEST........................................................................................................
TROUBLESHOOTING GUIDE...................................................................................................
TABLE 2 OHMMETER MEASUREMENTS................................................................................
PARTS IDENTIFICATION:
MICROPAK CONTROLLER PARTS DIAGRAM / PARTS LIST...............................................
A11789-01 STAND-ALONE CONTROL / POWER SUPPLY
ASSEMBLY/PARTS LIST............................................................................................................
MICROPAK STAND-ALONE CONTROL / POWER SUPPLY
MODEL IDENTIFICATION..........................................................................................................
A11789-01 STAND-ALONE CONTROL / POWER SUPPLY SCHEMATIC.............................
WARRANTY POLICIES:
LIMITED WARRANTY..................................................................................................................
17-18
18-19
20-23
20
20
21-22
23
24-30
24-25
26-28
29
30
31
31
MicroPak Controller - Safety
SAFETY
Ransburg
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read and
understand all of the technical and safety literature for your Ransburg products. This manual
contains information that is important for you to
know and understand. This information relates to
USER SAFETY and PREVENTING EQUIPMENT
PROBLEMS. To help you recognize this information, we use the following symbols. Please pay
particular attention to these sections.
A WARNING! states information to alert you
to a situation that might cause serious injury
if instructions are not followed.
A CAUTION! states information that tells how
to prevent damage to equipment or how to
avoid a situation that might cause minor injury.
A NOTE is information relevant to the procedure in progress.
W A R N I N G
!
The user MUST read and be familiar with
the Safety Section in this manual and the
Ransburg safety literature therein identied.
This manual MUST be read and thor-
oughly understood by ALL personnel who
operate, clean or maintain this equipment!
Special care should be taken to ensure that
the WARNINGS and safety requirements for
operating and servicing the equipment are
followed. The user should be aware of and
adhere to ALL local building and re codes
and ordinances as well as NFPA-33 SAFETY STANDARD, LATEST EDITION, prior
to installing, operating, and/or servicing this
equipment.
W A R N I N G
!
While this manual lists standard specications
and service procedures, some minor deviations
may be found between this literature and your
equipment. Differences in local codes and plant
requirements, material delivery requirements,
etc., make such variations inevitable. Compare
this manual with your system installation drawings and appropriate Ransburg equipment manuals to reconcile such differences.
Careful study and continued use of this manual will
provide a better understanding of the equipment
and process, resulting in more efcient operation,
longer trouble-free service and faster, easier
troubleshooting. If you do not have the manuals
and safety literature for your Ransburg system,
contact your local Ransburg representative or
Ransburg.
The hazards shown on the following pag-
es may occur during the normal use of this
equipment. Please read the hazard chart beginning on page 2.
1
CP-06-01.1
Ransburg
MicroPak Controller - Safety
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Fire Hazard
Improper or inadequate
operation and maintenance
procedures will cause a re
hazard.
Protection against inadvertent arcing that is capable of
causing re or explosion is
lost if any safety interlocks
are disabled during operation. Frequent Power Supply
or Controller shutdown indicates a problem in the system
requiring correction.
SAFEGUARDS
Tells how to avoid the hazard.
Fire extinguishing equipment must be present in
the spray area and tested periodically.
Spray areas must be kept clean to prevent the
accumulation of combustible residues.
Smoking must never be allowed in the spray
area.
The high voltage supplied to the atomizer must
be turned off prior to cleaning, ushing or maintenance.
When using solvents for cleaning:
• Those used for equipment ushing should
have ash points equal to or higher than
those of the coating material.
• Those used for general cleaning must have
ash points above 100°F (37.8°C).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, country, and local
codes. In addition, ventilation must be maintained during cleaning operations using ammable or combustible solvents.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between
the parts being coated and the applicator. A distance of 1 inch for every 10KV of output voltage
is required at all times.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but
only as instructed.
Non-factory replacement parts or unautho-
rized equipment modications may cause re or
injury.
If used, the key switch bypass is intended for
use only during setup operations. Production
should never be done with safety interlocks disabled.
Never use equipment intended for use in waterborne installations to spray solvent based materials.
The paint process and equipment should be
set up and operated in accordance with NFPA33, NEC, OSHA, local, country, and European
Health and Safety Norms.
CP-06-01.1
2
MicroPak Controller - Safety
Ransburg
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Explosion Hazard
Improper or inadequate operation and maintenance proce-
dures will cause a re hazard.
Protection against inadvertent
arcing that is capable of caus-
ing re or explosion is lost if
any safety interlocks are disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system requiring correction.
SAFEGUARDS
Tells how to avoid the hazard.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between
the parts being coated and the applicator. A distance of 1 inch for every 10KV of output voltage
is required at all times.
Unless specically approved for use in hazardous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2
hazardous areas, in accordance with NFPA-33.
Test only in areas free of ammable or combustible materials.
The current overload sensitivity (if equipped)
MUST be set as described in the corresponding section of the equipment manual. Protection against inadvertent arcing that is capable
of causing re or explosion is lost if the current
overload sensitivity is not properly set. Frequent power supply shutdown indicates a problem in the system which requires correction.
General Use and
Maintenance
Improper operation or maintenance may create a hazard.
Personnel must be properly
trained in the use of this equipment.
Always turn the control panel power off prior to
ushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no
objects are within the safe sparking distance.
Ensure that the control panel is interlocked with
the ventilation system and conveyor in accordance with NFPA-33, EN 50176.
Have re extinguishing equipment readily available and tested periodically.
Personnel must be given training in accordance
with the requirements of NFPA-33, EN 60079-0.
Instructions and safety precautions must be
read and understood prior to using this equipment.
Comply with appropriate local, state, and national codes governing ventilation, re protection, operation maintenance, and housekeeping. Reference OSHA, NFPA-33, EN Norms
and your insurance company requirements.
3
CP-06-01.1
Ransburg
MicroPak Controller - Safety
AREA
Tells where hazards
may occur.
Spray Area /
High Voltage
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materials and cause a re or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on conveyors or hangers that are properly grounded. The resistance between the part and earth
ground must not exceed 1 meg ohm. (Refer to
NFPA-33.)
Operators must be grounded. Rubber soled insulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator via conductive gloves or gloves with the
palm section cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
All electrically conductive objects in the spray
area, with the exception of those objects required by the process to be at high voltage, must
be grounded. Grounded conductive ooring
must be provided in the spray area.
Always turn off the power supply prior to ushing, cleaning, or working on spray system equipment.
Unless specically approved for use in hazardous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA-33.
CP-06-01.1
4
MicroPak Controller - Safety
Ransburg
AREA
Tells where hazards
may occur.
Electrical
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
High voltage equipment is utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may oc-
cur. Personnel are exposed to
high voltage during operation
and maintenance.
Protection against inadvertent
arcing that may cause a re or
explosion is lost if safety circuits
are disabled during operation.
Frequent power supply shutdown indicates a problem in the
system which requires correction.
An electrical arc can ignite coat-
ing materials and cause a re or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Unless specically approved for use in hazardous locations, the power supply, control cabinet,
and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas in accordance with NFPA-33 and EN
50176.
Turn the power supply OFF before working on
the equipment.
Test only in areas free of ammable or combustible material.
Testing may require high voltage to be on, but
only as instructed.
Production should never be done with the safety
circuits disabled.
Before turning the high voltage on, make sure no
objects are within the sparking distance.
Toxic Substances
Spray Area
Certain material may be harmful
if inhaled, or if there is contact
with the skin.
Explosion Hazard –
Incompatible Materials
Halogenated hydrocarbon sol-
vents for example: methylene
chloride and 1,1,1,-Trichloroethane are not chemically
compatible with the aluminum
that might be used in many system components. The chemical
reaction caused by these solvents reacting with aluminum
can become violent and lead to
an equipment explosion.
Follow the requirements of the Material Safety
Data Sheet supplied by coating material manufacturer.
Adequate exhaust must be provided to keep the
air free of accumulations of toxic materials.
Use a mask or respirator whenever there is a
chance of inhaling sprayed materials. The mask
must be compatible with the material being
sprayed and its concentration. Equipment must
be as prescribed by an industrial hygienist or
safety expert, and be NIOSH approved.
Aluminum is widely used in other spray application equipment - such as material pumps,
regulators, triggering valves, etc. Halogenated
hydrocarbon solvents must never be used with
aluminum equipment during spraying, ushing,
or cleaning. Read the label or data sheet for the
material you intend to spray. If in doubt as to
whether or not a coating or cleaning material is
compatible, contact your coating supplier. Any
other type of solvent may be used with aluminum
equipment.
5
CP-06-01.1
Ransburg
INTRODUCTION
MicroPak Controller - Introduction
GENERAL DESCRIPTION
The MicroPakTM Controller, is used to provide
voltage to the cascade inside the Spray Gun Assembly.
The MicroPak Controller together with the Spray
Gun Assembly and it’s Low Voltage Cable is a
System. It is unique in that it contains a built-in
DC Power Supply and is capable of operating
either 1 or 2 MicroPak control units.
The MicroPak uses a combination of proven
high voltage generation technology including microprocessor-based control with diagnostic and
communication functions. The processor circuit-
ry provides the maximum in applicator transfer
efciency.
SAFETY FEATURES
Voltage Control
The Over-Current setpoint can be monitored on
the μa Display by pressing the SET push-button
and holding for one second. It does provide a
hard shut-down if the output current exceeds the
setpoint. The kV setpoint is also displayed on the
kV display when the SET push-button is pressed
for one second.
CURRENT CONTROL
The current setpoint limits the maximum current
that the cascade can produce. The voltage set-
point sets the maximum voltage the cascade
can produce. The MicroPak will rst attempt to
achieve current output setpoint. If the voltage
setpoint is set low, then the voltage setpoint will
not allow the current setpoint to be achieved.
DISPLAYS
The front panel displays for output voltage and
current indicate the true outputs from the cascade or the tip voltage for indirect charge, and
waterborne applications. They are derived from
feedback signals in the low voltage cable between the controller and the cascade.
CP-06-01.1
6
MicroPak Controller - Introduction
Ransburg
SPECIFICATIONS
(At Sea-Level Conditions)
Environmental / Physical
Temp. Operating: (0o to 55o C)
Storage: (-40o C to 85o C)
Humidity: (95% Non-Condensing)
Cabinet Size: 13” Wide
19” Deep
7” Height
Weight: 19 lbs.
Electrical
DC Power Required: *
(per MicroPak) 24VDC at 2.5A
(fully loaded output),
HP404 Cascade
AC Electrical Requirements:
90-264 VAC @ 1.5 amps @
47/63 Hertz
NOTES
* DC power supplied from 24VDC built-in,
regulated power supy which has over-current
(40%) and over-voltage (20%) protection.
Controls:
Discrete signals available via I/O Module
(Part #76037-03)
Analog In: KV SET (0-10VDC)
OVER-CURRENT SET
(0-10VDC)
Discrete Out: HV ON (+24V)
HV READY (+24V)
OVER-CURRENT FAULT
(+24V)
Discrete In: HV RESET (+24V)
HV ON (+24V)
7
CP-06-01.1
Ransburg
INSTALLATION
MICROPAK INPUT
POWER
For non-conduit installations, plug the detachable AC line cord into the receptacle on the
rear of the MicroPak Controller. Plug the other
end of the line cord into a properly grounded
120 VAC outlet.
NOTE
> In general, conduit must be used for
approved AC installation, however, if national
and local codes permit, the AC power may
be supplied via the factory suppliedline cord.
MicroPak Controller - Installation
Figure 1: Terminal Block 1 (1TB)
3. Remove the mounting hardware from the AC
Inlet Receptacle and remove it from the rear of
the control unit.
4. Install the Conduit Adapter Plate (supplied)
(76453) in the hole where the AC Inlet Receptacle was removed (see Figure 2).
For installations where it is required to run the
AC input wiring in conduit, perform the following:
1. Ensure the AC line cord is unplugged and remove the top cover from the controller (see Figure 9).
2. Remove the AC Inlet Receptacle wiring from
1TB-L1, 1TB-N, and 1TB-Ground (see Figure 1
for AC input wiring locations).
W A R N I N G
!
> Always double check that the control
unit is unplugged from its AC outlet before
working with any internal wiring.
5. Install the AC line cord through the Conduit
Adapter Plate using conduit and wire to 1TB as
follows:
Hot/Line to 1TB-L1
Neutral/common to 1TB-N
Ground to 1TB-Ground
6. Reinstall top cover on controller.
CP-06-01.1
Figure 2: Installation of Conduit Adapter Plate
8
MicroPak Controller - Installation
Ransburg
SAFETY GROUND
Install the ground wire assembly supplied with
the MicroPak Controller from the ground stud on
the rear of the controller to a true earth ground.
For maximum noise immunity, cut the ground
wire assembly to the shortest length required
and reinstall the end lug before making connections.
C A U T I O N
!
The ground wire assembly MUST be con-
nected from the MicroPak Controller ground
stud to a true earth ground.
LOW VOLTAGE CABLE
Standard Low Voltage Cable
(A11791-XX)
Plug the connector of the low voltage cable assembly into the appropriate receptacle on the
rear of the controller (see Figure 3). P1 is the output for the leftmost MicroPak control unit, when
viewed from the front, and P2 is the output for
the rightmost MicroPak control unit, if installed.
When making the connection, line the red dot on
the connector with the red mark on the receptacle and push in until it clicks. To remove, simply
pull back on the knurled portion of the connector.
Attach the low voltage cable(s) to the stress relief bar using TR-SSEM-200 cable ties (supplied)
as shown in Figure 3.
Junction Box Cables
(A11498-XX and A11356-XX)
The spray gun can be ordered with special low
voltage cables (A11498-XX and A11356-XX)
for splicing to a junction box. This is sometimes
done in the eld, to reduce the amount of cable
that has to be replaced if a failure of the cable
occurs. The control unit and gun ends of these
cables attach as described in the standard low
voltage cable section above. Follow the instruc-
tions below to wire the junction box ends of these
cables:
Junction Box in Hazardous Location
If the junction box is in the hazardous location,
an explosion-proof junction box must be used. In
this case, connect the numbered wires of cable
A11356-XX to the same numbered wire of cable
A11498-XX using a terminal strip inside the explosion-proof junction box. Ensure the junction
box is grounded to earth ground. Connect wire
18 (braid) of cable A11498-XX to the junction box
(ground). Seal the cable in the explosion-proof
junction box using appropriate explosion-proof
ttings and sealing compound. The exposed
area of the cable braids must be located on the
junction box side of the sealing compound.
Junction Box in Non-Hazardous
Location
If the junction box is in a non-hazardous location,
then it is not necessary to use an explosion-proof
junction box. In this case, use the supplied cable
gland (A11357-02) and gland nut (A11358-02) to
secure the cables at their entry and exit to the
junction box. Install the cable gland in the junction box and position the cable so that the spring
of the gland makes contact to the exposed braid
of the cable when the gland nut is tightened.
Ensure the junction box is grounded to earth
ground. Connect the numbered wires of cable
A11356-XX to the same numbered wire of cable
A11498-XX using a terminal strip inside the junc-
tion box. The braid of cable A11498-XX will be
grounded through its contact to the cable gland
spring and the grounded junction box. Wire 18,
therefore is unnecessary and may be trimmed
off. Connection in this manner will ensure maximum noise immunity.
9
CP-06-01.1
Loading...